Casting processes involve the use of molten material, usually metal. This molten material is then poured into a mold cavity that takes the form of the finished part. The molten material then cools, with heat generally being extracted via the mold, until it solidifies into the desired shape. In this chapter we will talk about the introduction advantages and limitations of the Casting process.
Introduction
Process in which molten metal flows by gravity or other force into a mold where it solidifies in the shape of the mold cavity is called Casting. The term casting also applies to the part made in the process. Castings are used in locomotives, cars trucks, aircraft, office buildings, factories, schools, and homes.
Advantages
The metal casting process is extensively used in manufacturing because of its many advantages:
1. Molten material can flow into very small sections so that intricate shapes can be made by this process. As a result, many other operations, such as machining, forging, and welding can be minimized or eliminated. This renders it a very economical process.
2. Any ferrous or non-ferrous may be cast.
3. As the metal can be placed exactly where it is required, a large saving in weight can be achieved.
4. The necessary tools required for casting molds are very simple and inexpensive. As a result, for production of a small lot, is the ideal process.
5. Casting is a unique process to make certain parts.
6. Size and weight of the product are not a limitation for the casting process.
Limitations
1. Dimensional accuracy and surface finish of the castings made by sand casting processes are a limitation to this technique. Many new casting processes have been developed which can take into consideration the aspects of dimensional accuracy and surface finish. Some of these processes are the die casting process, investment casting process, vacuum-sealed molding process, and shell molding process.
2. The metal casting process is a labor-intensive process
